Printed circuit board connection

ABSTRACT

An electronic device, comprising an improved printed circuit board connection for connecting a first printed circuit board to a second printed circuit board in a manner that permits physical engagement at a different position than the electrical engagement, and a method for making the improved printed circuit board connection with precision in alignment. In one embodiment, the first printed circuit board includes an end portion configured to engage with a member of a connector on the second printed circuit board. The end portion and the member engage along concave portions of the end portion and convex portions of the member. When engaged, the end portion and the member align wires of the first printed circuit board with terminals of the connector.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 11/432,132,filed May 11, 2006, which is based upon and claims the benefit ofpriority from Japanese Patent Application No. 2005-138698, filed May 11,2005, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

One embodiment of the invention relates to a circuit board, such as aflexible printed circuit board or rigid printed circuit board, aconnector connectable to the circuit board, and an electronic devicewith the circuit board and connector.

2. Description of the Related Art

In accordance with the development of downsizing and high integration ofelectronic devices, the electronic units incorporated in the electronicdevices are also reduced in size. Similarly, reduction in size andpitch, high integration and high accuracy are required of flexibleprinted circuit (FPC) boards for connecting the electronic units, andconnectors (FPC connectors) connected to the FPCs.

For instance, to appropriately mount an FPC on an FPC connector, theiroutlines are processed for positioning. Outline processing is oftenperformed on the opposite ends of the FPC (the opposite ends that arebrought into contact with the insertion hole of the FPC connector whenthe FPC is inserted therein). In this case, the outlines of the oppositeends must be processed highly accurately so as to prevent contactfailure from occurring at the opposite ends.

Jpn. Pat. Appln. KOKAI Publication No. 2003-317830 (see, for example,FIG. 8) discloses a structure in which two boards have respectiveprojecting contact portions, through which the wiring patterns of theboards are coupled to each other.

In general, the outline processing of the opposite ends of an FPC isperformed after wiring is formed on the FPC, and may well cause errors.Even a slight error may cause the contact position to be greatlydeviated from the correct position on a highly integrated narrow-pitchFPC wiring pattern, thereby causing electrical contact failure. This mayoccur in rigid printed circuit boards, as well as in FPCs.

Further, in the above-mentioned structure in which two boards haverespective projecting contact portions, through which their wiringpatterns are coupled to each other, electrical contact failure mayeasily occur because of the influence of dust or adhesive, etc. When aclearance is defined between the boards, contact failure may also easilyoccur.

BRIEF DESCRIPTION OF THE DRAWINGS

A general architecture that implements the various feature of theinvention will now be described with reference to the drawings. Thedrawings and the associated descriptions are provided to illustrateembodiments of the invention and not to limit the scope of theinvention.

FIG. 1 is an exemplary schematic perspective view illustrating theoutward appearance of an electronic device according to an embodiment ofthe invention;

FIG. 2 is an exemplary block diagram illustrating the systemconfiguration of the electronic device of FIG. 1;

FIG. 3 is an exemplary development useful in explaining the structuralelements related to various types of printed circuit boards employed inthe electronic device of FIG. 1;

FIG. 4 is an exemplary view illustrating a first structural example ofthe connecting portion between the FPC of FIG. 3 and an FPC connector;

FIG. 5 is an exemplary view illustrating a second structural example ofthe connecting portion between the FPC of FIG. 3 and an FPC connector;

FIG. 6 is an exemplary perspective view acquired when the FPC of FIG. 4is viewed in a different direction;

FIG. 7 is an exemplary perspective view acquired when the FPC connectorof FIG. 4 is viewed in a different direction;

FIG. 8 is an exemplary flowchart useful in explaining the procedure ofproducing the FPC; and

FIG. 9 is an exemplary flowchart useful in explaining the procedure ofproducing the FPC connector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Various embodiments according to the invention will be describedhereinafter with reference to the accompanying drawings. In general,according to one embodiment of the invention, there is provided animproved printed circuit board connection for connecting a first printedcircuit board to a second printed circuit board in a manner that permitsphysical engagement at a different position than the electricalengagement, and a method for making the improved printed circuit boardconnection with precision alignment. In one embodiment, the firstprinted circuit board includes an end portion configured to engage witha member of a connector on the second printed circuit board. The endportion and the member engage along concave portions of the end portionand convex portions of the member. When engaged, the end portion and themember align wires of the first printed circuit board with terminals ofthe connector.

Referring first to FIGS. 1 and 2, an electronic device according to theembodiment of the invention will be described. This electronic device isrealized as, for example, a notebook personal computer 10.

FIG. 1 is a perspective view illustrating the notebook personal computer10 in an open state. The computer 10 comprises a personal computer (PC)proper 11 and display unit 12. The display unit 12 incorporates a liquidcrystal display (LCD) 17, and the display screen of the LCD 17 ispositioned at substantially the center of the display unit 12.

The display unit 12 is attached to the PC proper 11 so that it can pivotbetween its open position and closed position. The PC proper 11 has athin box-shaped case, and includes a keyboard 13, a power button 14 forturning on and off the computer 10, an input operation panel 15 and atouch pad 16, etc., which are provided on the upper surface of the case.

The input operation panel 15 is an input device for inputting an eventcorresponding to a button pushed, and includes a plurality of buttonsfor activating a plurality of functions. These buttons include a TVactivation button 15A and digital versatile disc (DVD) activation button15B. The TV activation button 15A is used to activate a TV function forrecording and replaying broadcast program data, such as digital TVbroadcast programs. When a user has pushed the TV activation button 15A,an application program for executing the TV function is automaticallyactivated. The DVD activation button 15B is used to replay video contentrecorded on a DVD. When the user has pushed the DVD activation button15B, an application program for replaying video content is automaticallyactivated.

Referring to FIG. 2, the system configuration of the computer 10 will bedescribed.

As shown in FIG. 2, the computer 10 comprises a CPU 111, north bridge112, main memory (memory module) 113, graphics controller (module) 114,south bridge 119, BIOS-ROM 120, hard disk drive (HDD) 121, optical diskdrive (ODD) 122, digital TV broadcast tuner (module) 123, embeddedcontroller/keyboard controller IC (EC/KBC) 124 and network controller125, etc.

The CPU 111 is a processor for controlling the entire operation of thecomputer 10, and executes an operating system (OS) and variousapplication programs, such as a video replay application program, whichare loaded from the HDD 121 to the main memory 113.

The CPU 111 also executes the basic input-output system (BIOS) stored inthe BIOS-ROM 120. The BIOS is a program for hardware control.

The north bridge 112 is a bride device for connecting the local bus ofthe CPU 111 to the south bridge 119. The north bridge 112 contains amemory controller for controlling access to the main memory 113. Thenorth bridge 112 also has a function for communicating with the graphicscontroller 114 via, for example, an accelerated graphics port (AGP) bus.

The graphics controller 114 is a display controller for controlling theLCD 17 used as a display monitor for the computer 10. The graphicscontroller 114 generates a display signal, to be sent to the LCD 17,from image data written in a video memory (VRAM) 114A.

The south bridge 119 controls each device on a low pin count (LPC) bus,and each device on a peripheral component interconnect (PCI) bus. Thesouth bridge 119 contains an integrated drive electronics (IDE)controller for controlling the HDD 121 and ODD 122, and also has afunction for controlling the digital TV broadcast tuner 123, and afunction for controlling access to the BIOS-ROM 120.

The HDD 121 is a storing unit for storing various types of software anddata. The optical disk drive (ODD) 122 is a drive unit for driving adata storing media, such as a DVD, which stores video content. Thedigital TV broadcast tuner 123 is a receiver for receiving broadcastprogram data, such as digital TV broadcast programs, from the outside.

The embedded controller/keyboard controller IC (EC/KBC) 124 is aone-chip microcomputer including an embedded controller for powermanagement, and a keyboard controller for controlling the keyboard (KB)13 and touch pad 16. The embedded controller/keyboard controller IC(EC/KBC) 124 has a function for turning on and off the computer 10 inaccordance with the operation of the power button 14 by the user. Thenetwork controller 125 is a communication device for enablingcommunication with an external network, such as the Internet.

FIG. 3 is a development useful in explaining the structural elementsrelated to various types of printed circuit boards for use in thecomputer 10.

The computer 10 contains a main board (main PCB) 21. On the main PCB 21,there are provided FPC connectors 40A and 40B for mounting flexibleprinted circuit boards (FPCs) 30A and 30B that interface units with eachother, and connectors (or sockets) 41A and 41B for mounting variousmodules provided with rigid printed circuit boards.

As well as the main PCB 21, a sub PCB 22 and mini-PCB module 23 arecontained in the computer 10. An FPC connector 40C for fixing the FPC30B is attached to the sub PCB 22.

In the example of FIG. 3, each connector is of a right angle type (i.e.,a lateral mount type in which the corresponding printed circuit board isinserted perpendicularly to the direction in which each connector ismounted on the main PCB 21). However, each connector is not limited tothis type, and may be of a straight type (i.e., a longitudinal mounttype in which the corresponding printed circuit board is inserted in thesame direction in which each connector is mounted on the main PCB 21).

The FPCs 30A and 30B are flexible printed circuit boards in which acircuit formed by accurately etching, for example, copper foil issandwiched between polyimide films excellent in insulation and heatresistance. Each FPC is electrically connectable to the correspondingFPC connectors when the opposite end portions of each FPC are insertedinto insertion slits formed in the connectors.

The FPC 30A has its one end portion connected to the FPC connector 40Aprovided on the main PCB 21, and the other end portion connected to theFPC connector 40C provided on the sub PCB 22, and serves as an interfacebetween the main PCB 21 and sub PCB 22. The FPC 30B has its one endportion connected to the FPC connector 40B provided on the main PCB 21,and the other end portion connected to the FPC connector 40D provided atthe optical disk drive (ODD) 122, and serves as an interface between themain PCB 21 and ODD 122. The FPC connector 40D is connected to the ODD122 via a connector 42. The same way of connection as that of the ODD122 may be employed for the HDD 121.

The memory module 113, digital TV broadcast tuner module 123 andmini-PCB module 23 are fitted in the connectors 41A, 41B and 41C,respectively. Each module is provided with a rigid printed circuitboard. The rigid circuit board is not so flexible as the FPC. When anend portion of each rigid printed circuit board is inserted into, forexample, an insertion slit formed in the corresponding connector, eachcircuit board is electrically connectable to the correspondingconnector. The same way of connection as that of the modules 112, 123and 23 may be employed for the graphics controller module 114.

FIGS. 4 and 5 show examples of connections between each FPC and thecorresponding FPC connector shown in FIG. 3. Namely, the structure shownin FIG. 4 or 5 is employed in the connections between the FPC 30A andFPC connector 40A, between the FPC 30A and FPC connector 40C, betweenthe FPC 30B and FPC connector 40B, and between the FPC 30B and FPCconnector 40D. FIG. 4 shows a case where the terminal arrangement ofeach FPC connector is of a straight type, and FIG. 5 shows a case wherethe terminal arrangement of each FPC connector is of a staggered type.

FIG. 6 is a view acquired when the FPC 30 of FIG. 4 is viewed in adifferent direction. FIG. 7 is a view acquired when the FPC connector 40of FIG. 4 is viewed in a different direction. Specifically, FIG. 6 showsa state in which the reverse surface (the surface provided with wiring36) of the FPC 30 in FIG. 4 is directed upwardly. In FIG. 7, although itappears that nothing exists above a plate member 47, another platemember actually exists which cooperates with the plate member 47 to holdtherebetween the FPC 30 fitted in the FPC connector 40. This provides aninsertion slit for inserting the FPC 30 therein, and a housing structurefor covering the inserted FPC 30.

The FPC 30 in FIG. 4 corresponds to each of the FPC 30A and 30B in FIG.3. Further, the FPC connector 40 in FIG. 4 corresponds to each of theFPC connectors 40A, 40B and 40C.

The FPC connector 40 is of, for example, a right angle type, and employsa contact form called “downside contact” in relation to the electricalconnection of the FPC 30. Further, the FPC 30 is of a type correspondingto the contact form.

The FPC connector 40 has a member 45 engaged with an end portion 35 ofthe FPC 30 when the FPC 30 is fitted in the connector. The FPC connector40 also has a plurality of terminals 46 (formed of, for example, metalplate springs) electrically connectable to a plurality of wires 36,incorporated in the FPC 30, at different positions from the end portion35 of the FPC 30 via their respective contacts when the member 45 isengaged with the end portion 35.

The FPC 30 has the end portion 35 engaged with the member 45 of the FPCconnector 40 when it is fitted in the FPC connector 40. Further, the FPC30 also has the plurality of wires 36 electrically connectable to theplurality of terminals 46 of the FPC connector 40 at different positionsfrom the end portion 35 of the FPC 30 via their respective contacts whenthe end portion 35 is engaged with the member 45 of the FPC connector40. Assume here that the wires 36 are provided on the lower surface ofthe FPC 30 in the form of a copper pattern.

In particular, in the embodiment, the member 45 of the FPC connector 40has a plurality of semicircular convex portions 45 a, while the endportion 35 of the FPC 30 has a plurality of semicircular concaveportions 35 a. The semicircular convex portions 45 a and concaveportions 35 a are engaged to position the wires 36 and terminals 46.

The semicircular concave portions 35 a are formed through a drillingprocess on a PCB to acquire circular holes, and processing the circularholes into semicircular ones (e.g., by removing the portion of the PCBthat ranges from the center of the holes to the edge of the PCB). Thus,concave portions of highly positioning accuracy can be formed at lowcost, simply using an existing way of drilling. Further, the problem ofdisplacement can be avoided by performing the drilling process beforeforming the wires 36. Namely, the wires 36 are formed after formingcircular holes by drilling. In this case, the positions of the wires 36are determined with reference to the positions of the circular holes.

On the other hand, part of the member 45 is formed into the semicircularconvex portions 45 a by molding. By virtue of molding, the convexportions 45 a accurately engaged with the semicircular concave portions35 a can be easily formed. After forming the member 45 with the convexportions 45 a, the terminals 46 are formed. At this time, the positionsof the terminals 46 are determined from the positions of thesemicircular convex portions 45 a.

If the number of the concave portions 35 a and 45 a is set equal to thatof the wires 36 and terminals 46, positioning can be performed in unitsof terminals, which realizes more reliable positioning. However, thenumber is not limited to the above. For instance, the number of theconcave portions 35 a and 45 a may be reduced to half, or to two atminimum. Even in such cases, reliable positioning can be realized.

The structures of FIGS. 4 and 5 differ in two points. The first point isthat the terminals 46 in FIG. 4 are arranged in a straight manner, whilethe terminals 46′ in FIG. 5 are arranged in a staggered manner. Thesecond point is that the wires 36 in FIG. 4 are arranged in a straightmanner in accordance with the arrangement of the terminals 46, while thewires 36′ in FIG. 5 are arranged in a staggered manner in accordancewith the arrangement of the terminals 46′.

The structures shown in FIGS. 4 to 7 are also applicable to FPCs (notshown) contained in (for example, a head section repeatedly operating athigh speed and incorporated in) the ODD 122 or HDD 121 in FIG. 3.

Further, the structures of FIGS. 4 to 7 are also applicable to the rigidprinted circuit boards and corresponding connectors in FIG. 3. Namely,the structure shown in FIG. 4 or 5 can be employed in the connectionsbetween the memory module 113 and connector 41A, between the digital TVbroadcast tuner module 123 and connector 41B, and between the mini-PCBmodule 23 and connector 41C.

Referring then to FIG. 8, the procedure of manufacturing an FPC will bedescribed briefly.

Firstly, a copper-coated plate or copper-coated laminated plate forproducing an FPC is prepared (block A1). A drilling process is performedon the copper-coated plate or copper-coated laminated plate forconnecting the upper and lower surfaces thereof or the upper, inner andlower surfaces thereof, and another drilling process is performed forforming such semicircular concave portions as described above (blockS2). As a result, a plurality of circular holes is formed. After that,with reference to the positions of the circular holes, a plurality ofwires are formed on the copper-coated plate or copper-coated laminatedplate (block A3). Lastly, outline processing is executed on theresultant structure to finish an FPC as a final product. By outlineprocessing, the circular hole portions formed by drilling are formedinto semicircular hole portions (block A4).

Referring to FIG. 9, the procedure of manufacturing an FPC connectorwill be described briefly.

Firstly, components and materials for the FPC connector are prepared(block B1). Subsequently, molding is performed using, for example, aresin to form semicircular convex portions (block B2). After that, aplurality of terminals are formed with reference to the positions of thealready formed semicircular convex portions (block B3), and lastly, anFPC connector as a final product is finished (block B4).

The procedures of FIGS. 8 and 9 are also applicable to the production ofeach rigid printed circuit board and the corresponding connector.

As described above, in the embodiment, a plurality of semicircularconvex portions are formed at each connector, and a plurality ofsemicircular concave portions are formed at the corresponding printedcircuit board to be fitted in each connector, thereby realizing highlyaccurate positioning to prevent contact failure during the connection ofthe connector and board.

Although each connector employed in the embodiment is of the right angletype and downside-contact type, the convex structure is applicable tovarious types of connectors, such as a connector of the right angle typeand upside-contact type, a connector of the right angle type andupside/downside-contact type, a connector of a straight type andright-hand-contact type, a connector of the straight type andleft-hand-contact type, and a connector of the straight type andright-hand/left-hand-contact type. Further, the concave structure isalso applicable to printed circuit boards fitted in these connectors.

In addition, although in the embodiment, the electronic device is apersonal computer, the connector and printed circuit board forconnecting units are also applicable to other types of electronicdevices, such as PDAs, mobile phones, liquid crystal television sets,plasma television sets, mobile audio players, digital cameras andportable players.

As described above in detail, it is possible to realize highly accuratepositioning to prevent contact failure.

While certain embodiments of the inventions have been described, theseembodiments have been presented by way of example only, and are notintended to limit the scope of the inventions. Indeed, the novel methodsand systems described herein may be embodied in a variety of otherforms; furthermore, various omissions, substitutions and changes in theform of the methods and systems described herein may be made withoutdeparting from the spirit of the inventions. The accompanying claims andtheir equivalents are intended to cover such forms or modifications aswould fall within the scope and spirit of the inventions.

1. An electronic device, comprising: a connector comprising a member andterminals; a printed circuit board comprising an end portion andconductors; the member being configured to engage the end portion of theprinted circuit board, the member comprising a plurality ofsubstantially convex portions that are configured to align with theconductors on the printed circuit board when the member is engaged withthe end portion, each of the substantially convex portions beingsemicircular; the terminals being configured to be in electricalcommunication with the conductors at positions different from the memberwhen the member is engaged with the end portion, each of thesubstantially convex portions being positioned between adjacent ones ofthe terminals; the end portion being configured to engage the member ofthe connector, the end portion comprising substantially concave portionsthat are configured to align with the terminals on the connector whenthe end portion is engaged with the member, each of the substantiallyconcave portions being semicircular; and the conductors being configuredto be in electrical communication with the terminals at positionsdifferent from the end portion when the end portion is engaged with themember, each of the substantially concave portions being positionedbetween adjacent ones of the terminals when the end portion is engagedwith the member.
 2. The electronic device of claim 1, wherein thesubstantially concave portions comprise drilled surfaces.
 3. Theelectronic device of claim 1, wherein positions of the plurality ofconductors are determined with reference to positions of thesubstantially concave portions.
 4. The electronic device of claim 1,wherein the printed circuit board is a flexible printed circuit board.5. The electronic device of claim 1, wherein the printed circuit boardis a rigid printed circuit board.
 6. The electronic device of claim 1,wherein at least part of the member comprises molded substantiallyconvex portions.
 7. The electronic device of claim 1, wherein positionsof the plurality of terminals are determined with reference to positionsof the substantially convex portions.
 8. An electronic device,comprising: a connector comprising a member and terminals; a flexibleprinted circuit board comprising an end portion and conductors; themember being configured to engage the end portion of the flexibleprinted circuit board, the member comprising a plurality ofsubstantially convex portions that are configured to align with theconductors on the flexible printed circuit board when the member isengaged with the end portion, each of the substantially convex portionsbeing semicircular; the terminals being configured to be in electricalcommunication with the conductors at positions different from the memberwhen the member is engaged with the end portion, each of thesubstantially convex portions being positioned between adjacent ones ofthe terminals; the end portion being configured to engage the member ofthe connector, the end portion comprising substantially concave portionsthat are configured to align with the terminals on the connector whenthe end portion is engaged with the member, each of the substantiallyconcave portions being semicircular; the conductors being configured tobe in electrical communication with the terminals at positions differentfrom the end portion when the end portion is engaged with the member,each of the substantially concave portions being positioned betweenadjacent ones of the terminals when the end portion is engaged with themember; and the flexible printed circuit board being flexed when the endportion of the flexible printed circuit board is engaged with the memberof the connector.
 9. The electronic device of claim 8, furthercomprising first and second connectors each having same structures assaid connector, the flexible printed circuit board being flexed when afirst end portion of the flexible printed circuit board is engaged witha member of the first connector and a second end portion of the flexibleprinted circuit board is engaged with a member of the second connector.10. A connector, comprising: a member configured to engage an endportion of a printed circuit board, and comprising a plurality ofsubstantially convex portions configured to align with conductors on theprinted circuit board when the member is engaged with the end portion,each of the substantially convex portions being semicircular; and aplurality of terminals; wherein a portion of said plurality of terminalsare configured to be in electrical communication with the conductors atpositions different from the member when the member is engaged with theend portion, each of the substantially convex portions being positionedbetween adjacent ones of the remaining plurality of terminals.